Game ball with synthetic leather cover

Abstract

A game ball having a high end synthetic leather cover formed from a non-woven fiber mat impregnated with polyurethane. In one embodiment, the game ball is a football and the fibers in the backing of the cover material have a denier of about 0.1 or less. In another embodiment, the game ball cover has a dual layer coating to impart to the cover good pebble retention. The first layer has a Shore A hardness of at least about 65, and the second layer surrounding the first layer has a Shore A hardness lower than the hardness of the first layer. The game ball, which can be formed to meet association specifications, has properties of softness and durability comparable to those of a genuine full grain leather game ball.

What is claimed is: 
     
       1. A game ball, comprising: a center,   a cover secured over the center, the cover including a backing comprising a fiber reinforced polyurethane material, a first coating layer formed over the backing having a Shore A hardness of at least about 65, and a second coating layer surrounding the first coating layer, the second coating layer having a Shore A hardness which is lower than the Shore A hardness of the first coating layer.   
     
     
       2. A game ball according to claim 1, wherein the first coating layer has a thickness of about 1-15 mils. 
     
     
       3. A game ball according to claim 1, wherein the second coating layer has a thickness of about 0.1-10 mils. 
     
     
       4. A game ball according to claim 1, wherein the sum of the thicknesses of the first and second coating layers is about 1-25 mils. 
     
     
       5. A game ball according to claim 1, wherein the first coating layer has a Shore hardness of about 65A-60D. 
     
     
       6. A game ball according to claim 1, wherein the second coating layer has a Shore A hardness of about 30-65. 
     
     
       7. A game ball according to claim 1, wherein the fiber reinforced polyurethane material comprises fibers having an average denier of 0.1 or less. 
     
     
       8. A game ball according to claim 1, wherein the fiber reinforced polyurethane material comprises fibers having an average denier of 0.02 or less. 
     
     
       9. A game ball according to claim 1, wherein the fiber reinforced polyurethane material comprises fibers having an average denier of 0.01 or less. 
     
     
       10. A game ball according to claim 1, wherein the backing fibers contain at least one material selected from the group consisting of a polyamide and a polyester. 
     
     
       11. A game ball according to claim 1, wherein the game ball cover has embossed pebbles and the first coating layer has properties of hardness and thickness sufficient to provide the pebbles with a retention level of at least 80% of their molded set. 
     
     
       12. A game ball according to claim 1, wherein the cover has an embossed texture. 
     
     
       13. A game ball according to claim 1, wherein the first coating layer has a Sward rocker hardness (ASTM-D2134) of 25-60. 
     
     
       14. A game ball according to claim 1, wherein the second coating layer has a Sward rocker hardness (ASTM-D2134) of 10-30. 
     
     
       15. A method of making a game ball, comprising: obtaining a game ball center,   securing a cover over the center, the cover including a backing comprising a fiber reinforced polyurethane material, a first coating layer formed over the backing having a Shore A hardness of about 65, and a second coating layer surrounding the first coating layer, the second coating layer having a Shore A hardness which is lower than the Shore A hardness of the first coating layer.